US7601229B2 - Process for producing soft magnetism material, soft magnetism material and powder magnetic core - Google Patents

Process for producing soft magnetism material, soft magnetism material and powder magnetic core Download PDF

Info

Publication number
US7601229B2
US7601229B2 US10/595,314 US59531404A US7601229B2 US 7601229 B2 US7601229 B2 US 7601229B2 US 59531404 A US59531404 A US 59531404A US 7601229 B2 US7601229 B2 US 7601229B2
Authority
US
United States
Prior art keywords
magnetic particles
metal magnetic
heat treatment
shaped body
microns
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related, expires
Application number
US10/595,314
Other languages
English (en)
Other versions
US20070102066A1 (en
Inventor
Haruhisa Toyoda
Hirokazu Kugai
Kazuhiro Hirose
Naoto Igarashi
Takao Nishioka
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumitomo Electric Industries Ltd
Original Assignee
Sumitomo Electric Industries Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2004024256A external-priority patent/JP2005142522A/ja
Application filed by Sumitomo Electric Industries Ltd filed Critical Sumitomo Electric Industries Ltd
Assigned to SUMITOMO ELECTRIC INDUSTRIES, LTD. reassignment SUMITOMO ELECTRIC INDUSTRIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HIROSE, KAZUHIRO, KUGAI, HIROKAZU, IGARASHI, NAOTO, TOYODA, HARUHISA, NISHIOKA, TAKAO
Publication of US20070102066A1 publication Critical patent/US20070102066A1/en
Application granted granted Critical
Publication of US7601229B2 publication Critical patent/US7601229B2/en
Expired - Fee Related legal-status Critical Current
Adjusted expiration legal-status Critical

Links

Images

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0246Manufacturing of magnetic circuits by moulding or by pressing powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/33Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials mixtures of metallic and non-metallic particles; metallic particles having oxide skin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy

Definitions

  • the present invention relates to a soft magnetic material, a method for making the same, and a dust core. More specifically, the present invention relates to: a method for making a soft magnetic material using compound magnetic particles formed from metal magnetic particles and insulation coating covering the metal magnetic particles; a soft magnetic material formed from metal magnetic particles; and a dust core formed using this soft magnetic material.
  • Japanese Laid-Open Patent Publication Number 2002-246219 presents a dust core and method for making the same that allows magnetic properties to be maintained even under high-temperature environments (Patent Document 1).
  • a predetermined amount of polyphenylene sulfide (PPS resin) is mixed with an atomized iron powder coated with phosphoric acid, and this is then compressed.
  • PPS resin polyphenylene sulfide
  • the obtained shape body is heated in the open air for 1 hour at 320 deg C., and then for 1 hour at 240 deg C.
  • the structure is then cooled to form the dust core.
  • Patent Document 1 Japanese Laid-Open Patent Publication Number 2002-246219
  • Increasing the heat treatment applied to the shaped body may be one way to adequately reduce distortions inside the dust core.
  • the phosphoric acid compound covering the atomized iron particles does not have high heat resistance, leading it to degrade under heat treatment at high temperatures. This results in increased eddy current loss between the atomized iron particles covered with phosphoric acid, and this may lead to reduced permeability in the dust core.
  • the object of the present invention is to overcome the problems described above and to provide a soft magnetic material with desired magnetic properties, a method for making the same, and a dust core.
  • a method for making soft magnetic material includes: a first heat treatment step applying a temperature of at least 400 deg C. and less than 900 deg C. to metal magnetic particles; a step for forming a plurality of compound magnetic particles in which said metal magnetic particles are surrounded by insulation film; and a step for forming a shaped body by compacting a plurality of compound magnetic particles.
  • the first heat treatment performed on the metal magnetic particles reduces distortions (dislocations, defects) in the metal magnetic particles ahead of time.
  • the advantages from the first heat treatment are sufficiently obtained when the heat treatment temperature is at least 400 deg C. If the heat temperature is less than 900 deg C., the metal magnetic powders are prevented from being sintered and solidifying. If the metal magnetic powders are sintered, the solidified metal magnetic particles must be mechanically broken up, possibly leading to new distortions in the metal magnetic particles. By setting the heat treatment temperature to less than 900 deg C., this type of problem can be avoided.
  • the shaped body By performing the first heat treatment, almost all distortions present in the shaped body become products of the compaction operation. Thus, distortions can be reduced compared to when the first heat treatment is not performed. As a result, desired magnetic properties with increased permeability and reduced coercivity can be provided. Also, since distortions in the metal magnetic particles are reduced, the compound magnetic particles are made more easy to deform during compaction. As a result, the shaped body can be formed with the multiple compound magnetic particles meshed against each other with no gaps, thus increasing the density of the shaped body.
  • the first heat treatment step prefferably includes a step for heat treating the metal magnetic particles at a temperature of at least 700 deg C. and less than 900 deg C.
  • the first heat treatment can further reduce distortions present in the metal magnetic particles.
  • the second heat treatment step applying a temperature of at least 200 deg C. and no more than a thermal decomposition temperature of the insulation film to the shaped body.
  • the second heat treatment can further reduce distortions present in the metal magnetic particles. Since the distortions in the metal magnetic particles have already been reduced ahead of time, almost all the distortions in the shaped body are the result of pressure applied in a single direction to the compound magnetic particles during compaction. Thus, the distortions in the shaped body exist without complex interactions with each other.
  • distortions in the shaped body can be adequately reduced even with a relatively low temperature that is no more than the thermal decomposition temperature of the insulation film, e.g., no more than 500 deg C. in the case of a phosphoric acid based insulation film.
  • the temperature of the heat treatment is no more than the thermal decomposition temperature of the insulation film, there is no deterioration of the insulation film surrounding the metal magnetic particles. As a result, inter-particle eddy current loss generated between the compound magnetic particles can be reliably reduced.
  • the heat treatment temperature to be at least 200 deg C., the advantages of the second heat treatment can be adequately obtained.
  • the step for forming the shaped body prefferably includes a step for forming the shaped body in which the plurality of compound magnetic particles is bonded by organic matter.
  • organic matter is interposed between the compound magnetic particles. Since the organic matter acts as a lubricant during compaction, destruction of the insulation film can be prevented.
  • the first heat treatment step includes a step for setting a coercivity of the metal magnetic particles to be no more than 2.0 ⁇ 10 2 A/m.
  • the first heat treatment operation reduces the coercivity of the metal magnetic particles to no more than 2.0 ⁇ 10 2 A/m, thus further improving the increase in permeability and the reduction in coercivity of the shaped body.
  • the first heat treatment step includes a step for setting a coercivity of the metal magnetic particles to be no more than 1.2 ⁇ 10 2 A/m.
  • the first heat treatment step includes a step for heat treating the metal magnetic particle having a particle diameter distribution that is essentially solely in a range of at least 38 microns and less than 355 microns.
  • the particle diameter distribution of the metal magnetic particles can be set to at least 38 microns so that the influence of “stress-strain due to surface energy” can be limited.
  • This “stress-strain due to surface energy” refers to the stress-strain generated due to deformations and defects present on the surface of the metal magnetic particles, and its presence can obstruct domain wall displacement. By limiting this influence, the coercivity of the shaped body can be reduced and iron loss resulting from hysteresis loss can be reduced.
  • the particle diameter distribution at least 38 microns the drawing together of metal magnetic particles in clumps can be prevented. Also, by having the particle diameter distribution at less than 355 microns, it is possible to reduce eddy current loss within the metal magnetic particles. As a result, iron loss in the shaped body caused by eddy current loss can be reduced.
  • the first heat treatment step includes a step for heat treating the metal magnetic particle having a particle diameter distribution that is essentially solely in a range of at least 75 microns and less than 355 microns.
  • a step for heat treating the metal magnetic particle having a particle diameter distribution that is essentially solely in a range of at least 75 microns and less than 355 microns.
  • a soft magnetic material according to the present invention includes multiple metal magnetic particles.
  • the metal magnetic particles have a coercivity of no more than 2.0 ⁇ 10 2 A/m and the metal magnetic particles have a particle diameter distribution that is essentially solely in a range of at least 38 microns and less than 355 microns.
  • the metal magnetic particles serving as the raw material for the shaped body have a low coercivity of 2.0 ⁇ 10 2 A/m. Also, since the metal magnetic particles have a particle diameter distribution that is essentially solely in a range of at least 38 microns and less than 355 microns, the influence of “stress-strain due to surface energy” can be limited, and the eddy current loss within the metal magnetic particles can be reduced. Thus, when a shaped body is made using the soft magnetic material of the present invention, both hysteresis loss and eddy current loss are reduced, resulting in reduced iron loss in the shaped body.
  • the metal magnetic particles it is more preferable for the metal magnetic particles to have a coercivity of no more than 1.2 ⁇ 10 2 A/m. It is more preferable for the metal magnetic particles to have a particle diameter distribution that is essentially solely in a range of at least 75 microns and less than 355 microns.
  • the soft magnetic material includes a plurality of compound magnetic particles containing the metal magnetic particles and insulation film surrounding surfaces of the metal magnetic particles. With this soft magnetic material, the use of the insulation film makes it possible to limit eddy current flow between metal magnetic particles. This makes it possible to reduce iron loss resulting from eddy currents between particles.
  • the coercivity of a dust core made using any of the soft magnetic materials described above is no more than 1.2 ⁇ 10 2 A/m. With this dust core, the coercivity of the dust core is adequately low so that hysteresis loss can be reduced. As a result, a dust core with soft magnetic material can be used even in low-frequency ranges, where the proportion of hysteresis loss in iron loss is high.
  • the present invention provides a soft magnetic material, a method for making the same, and a dust core that provides desired magnetic properties.
  • FIG. 1 is a simplified detail drawing of a shaped body made using a method for making a soft magnetic material according to a first embodiment of the present invention.
  • FIG. 2 is a graph showing the relationship between the temperature of heat treatment performed on the metal magnetic particles and the maximum permeability of a shaped body.
  • FIG. 3 is a graph showing the relationship between the temperature of heat treatment performed on the metal magnetic particles and the coercivity of a shaped body.
  • a shaped body is formed from: multiple compound magnetic particles 30 formed a metal magnetic particle 10 and an insulation film 20 surrounding the surface of the metal magnetic particle 10 ; and an organic matter 40 interposed between the compound magnetic particles 30 .
  • the compound magnetic particles 30 are bonded to each other by the organic matter 40 or by the engagement of the projections and indentations of the compound magnetic particles 30 .
  • the shaped body in FIG. 1 is made by first preparing the metal magnetic particles 10 .
  • the metal magnetic particle 10 can be formed from, e.g., iron (Fe), an iron (Fe)-silicon (Si)-based alloy, an iron (Fe)-nitrogen (N)-based alloy, an iron (Fe)-nickel (Ni)-based alloy, an iron (Fe)-carbon (C)-based alloy, an iron (Fe)-boron (B)-based alloy, an iron (Fe)-cobalt (Co)-based alloy, an iron (Fe)-phosphorous (P)-based alloy, an iron (Fe)-nickel (Ni)-cobalt (Co)-based alloy, or an iron (Fe)-aluminum (Al)-Silicon (Si)-based alloy.
  • the metal magnetic particle 10 can be a single metal or an alloy.
  • the mean particle diameter of the metal magnetic particle 10 is at least 5 microns and no more than 300 microns. With a mean particle diameter of at least 5 microns for the metal magnetic particle 10 , oxidation of the metal becomes more difficult, thus improving the magnetic properties of the soft magnetic material. With a mean particle diameter of no more than 300 microns for the metal magnetic particle 10 , the compressibility of the mixed powder is not reduced during the pressurized compacting operation, described later. This provides a high density for the shaped body obtained from the pressurized compacting operation.
  • the mean particle diameter referred to here indicates a 50% particle diameter D, i.e., with a particle diameter histogram measured using the sieve method, the particle diameter of particles starting from the lower end of the histogram that have a mass that is 50% of the total mass.
  • the particle diameters of the metal magnetic particles 10 are effectively distributed solely in the range of at least 38 microns and less than 355 microns.
  • metal magnetic particles 10 from which particles with particle diameters of less than 38 microns and particles diameters of at least 355 microns have been forcibly excluded are used. It is more preferable for the particle diameters of the metal magnetic particles 10 to be effectively distributed solely in the range of at least 75 microns and less than 355 microns.
  • heat treatment with a temperature of at least 400 deg C. and less than 900 deg C. is applied to the metal magnetic particles 10 . It is preferable for the heat treatment temperature to be at least 700 deg C. and less than 900 deg C. Before heat treatment, there are a large number of distortions (dislocations, defects) inside the metal magnetic particles 10 . Applying heat treatment on the metal magnetic particles 10 makes it possible to reduce these distortions.
  • the compound magnetic particles 30 is made by forming the insulation film 20 on the metal magnetic particle 10 .
  • the insulation film 20 can be formed by treating the metal magnetic particle 10 with phosphoric acid.
  • the insulation film 20 it is also possible to form the insulation film 20 so that it contains an oxide.
  • oxide insulators such as: iron phosphate containing phosphorous and iron; manganese phosphate; zinc phosphate; calcium phosphate; aluminum phosphate; silicon oxide; titanium oxide; aluminum oxide; and zirconium oxide.
  • the insulation film 20 serves as an insulation layer between the metal magnetic particles 10 . Coating the metal magnetic particle 10 with the insulation film 20 makes it possible to increase the electrical resistivity p of the soft magnetic material. As a result, the flow of eddy currents between the metal magnetic particles 10 can be prevented and iron loss in the soft magnetic material resulting from eddy currents can be reduced.
  • the thickness of the insulation film 20 is at least 0.005 microns and no more than 20 microns.
  • the thickness of the insulation film 20 is at least 0.005 microns, it is possible to efficiently limit energy loss resulting from eddy currents.
  • setting the thickness of the insulation film 20 to be no more than 20 microns prevents the proportion of the insulation film 20 in the soft magnetic material from being too high. As a result, significant reduction in the magnetic flux density of the soft magnetic material can be prevented.
  • a mixed powder is obtained by mixing the compound magnetic particles 30 and the organic matter 40 .
  • mixing method There are no special restrictions on the mixing method. Examples of methods that can be used include: mechanical alloying, a vibrating ball mill, a planetary ball mill, mechano-fusion, coprecipitation, chemical vapor deposition (CVD), physical vapor deposition (PVD), plating, sputtering, vaporization, and a sol-gel method.
  • Examples of materials that can be used for the organic matter 40 include: a thermoplastic resin such as thermoplastic polyimide, a thermoplastic polyamide, a thermoplastic polyamide-imide, polyphenylene sulfide, polyamide-imide, polyether sulfone, polyether imide, or polyether ether ketone; a non-thermoplastic resin such as high molecular weight polyethylene, wholly aromatic polyester, or wholly aromatic polyimide; and higher fatty acid based materials such as zinc stearate, lithium stearate, calcium stearate, lithium palmitate, calcium palmitate, lithium oleate, and calcium oleate. Mixtures of these can be used as well.
  • a thermoplastic resin such as thermoplastic polyimide, a thermoplastic polyamide, a thermoplastic polyamide-imide, polyphenylene sulfide, polyamide-imide, polyether sulfone, polyether imide, or polyether ether ketone
  • a non-thermoplastic resin such as high
  • the proportion of the organic matter 40 relative to the soft magnetic material is more than 0 and no more than 1.0 percent by mass.
  • the proportion of the organic matter 40 can be kept at least a fixed value. This makes it possible to obtain a soft magnetic material with a higher magnetic flux density.
  • the resulting mixed powder is placed in a die and compacted at a pressure of, e.g., 700 MPa-1500 MPa. This compacts the mixed powder and provides a shaped body. It is preferable for the compacting to be performed in an inert gas atmosphere or a decompression atmosphere. This prevents the mixed powder from being oxidized by the oxygen in the air.
  • the organic matter 40 When compacting, the organic matter 40 serves as a buffer between the compound magnetic particles 30 . This prevents the insulation films 20 from being destroyed by the contact between the compound magnetic particles 30 .
  • the shaped body obtained by compacting is heat treated at a temperature of at least 200 deg C. and no more than the thermal decomposition temperature of the insulation film 20 .
  • the thermal decomposition temperature of the insulation film 20 is 500 deg C. This heat treatment is performed in order to reduce distortions formed inside the shaped body during the compacting operation.
  • the compound magnetic particles 30 tends to easily deform during compaction.
  • the shaped body can be formed with no gaps between the interlocking compound magnetic particles 30 as shown in FIG. 1 . This makes it possible to provide a high density for the shaped body and high magnetic permeability.
  • the insulation film 20 since heat treatment is performed on the shaped body at a relatively low temperature, the insulation film 20 does not deteriorate. As a result, the insulation films 20 cover the metal magnetic particles 10 even after heat treatment, and the insulation films 20 reliably limit the flow of eddy currents between the metal magnetic particles 10 . It is more preferable for the shaped body obtained by compaction to be heat treated at a temperature of at least 200 deg C. and no more than 300 deg C. This makes it possible to further limit deterioration of the insulation film 20 .
  • the shaped body shown in FIG. 1 is completed by following the steps described above.
  • the mixing of the organic matter 40 into the compound magnetic particles 30 is not a required step. It is also possible to not mix the organic matter 40 and perform compaction on just the compound magnetic particles 30 .
  • a method for making a soft magnetic material according to an embodiment of the present invention includes: a first heat treatment step heating the metal magnetic particles 10 at a temperature of at least 400 deg C. and less than 900 deg C.; a step for forming multiple compound magnetic particles 30 in which the metal magnetic particle 10 is surrounded by the insulation film 20 ; a step for forming a shaped body by compacting the multiple compound magnetic particles 30 .
  • the method for making the soft magnetic material further includes a second heat treatment step performed on the shaped body at a temperature of at least 200 deg C. and no more than the temperature of thermal decomposition of the insulation film 20 .
  • a method for making a soft magnetic material includes: a first heat treatment step applied to multiple metal magnetic particles 10 at a temperature of at least 400 deg C. and less than 900 deg C.; and a step for forming a shaped body by compacting the multiple metal magnetic particles 10 .
  • heat treatment is performed on the metal magnetic particles 10 at a predetermined temperature range before the metal magnetic particles 10 are coated with the insulation film 20 .
  • This heat treatment operation is preferable because it allows the shaped body to be formed with low distortion while not resulting in deterioration of the insulation film 20 . Also, by performing further heat treatment to the shaped body, distortion in the shaped body can be further reduced. As a result, desired magnetic properties with increased permeability and reduced coercivity can be provided.
  • the metal magnetic particles 10 are obtained through the method for making soft magnetic material described above with heat treatment performed at a temperature of at least 400 deg C. and less than 900 deg C.
  • the particle diameters of the metal magnetic particles 10 have an effective distribution solely in the range of at least 38 microns and less than 355 microns.
  • the soft magnetic material and method for making soft magnetic material according to the present invention can be used to make products such as dust cores, choke coils, switching power supply elements, magnetic heads, various types of motor parts, automotive solenoids, various types of magnetic sensors, and various types of electromagnetic valves.
  • a first example described below was performed to evaluate the method of making soft magnetic material.
  • the shaped body shown in FIG. 1 was prepared according to the production method described previously.
  • iron powder from Hoganas Corp. product name ASC 100.29
  • Heat treatment was performed on the metal magnetic particles 10 at various temperature conditions from 100 deg C. to 1000 deg C. Heat treatment was performed for 1 hour in hydrogen or inert gas. When the coercivity of the metal magnetic particle 10 was measured after heat treatment, values of less than 2.5 oersteds were found.
  • a phosphate film was coated over the metal magnetic particle 10 to serve as the insulation film 20 to form the compound magnetic particles 30 .
  • Compound magnetic particles 30 in which heat treatment was not performed on the metal magnetic particles 10 were also prepared.
  • the compound magnetic particles 30 was placed in a die and compacted without mixing in the organic matter 40 .
  • a pressure of 882 MPa was used.
  • the maximum permeability and coercivity of the obtained shaped body was measured.
  • heat treatment was performed on the shaped body for 1 hour at a temperature of 300 deg C. The maximum permeability and coercivity of the shaped body was then measured again.
  • Table 1 shows the measured maximum permeabilities and coercivities.
  • Table 1 shows the measured maximum permeabilities and coercivities.
  • the measurements for heat treatment at 30 deg C. were performed for the metal magnetic particles 10 that did not undergo heat treatment.
  • applying heat treatment to the metal magnetic particles 10 at temperatures of at least 400 deg C. and less than 900 deg C. increased the maximum permeability and reduced the coercivity for the shaped body before heat treatment.
  • advantages were more prominent for maximum permeability compared to coercivity.
  • maximum permeability was roughly maximum and coercivity was roughly minimum when heat treatment was performed on the metal magnetic particles 10 at temperatures of at least 700 deg C.
  • heat treatment was performed at temperatures of 900 deg C. and 1000 deg C., the metal magnetic particles 10 were partially sintered, preventing these sections from being used in the next step. Almost no differences were observed in maximum permeability and coercivity compared to when heat treatment was performed at a temperature of 850 deg C.
  • the maximum permeability of the shaped body could be further increased and the coercivity could be further reduced. As can be seen from FIG. 2 , these further increases in maximum permeability were greater when the heat treatment temperature for the metal magnetic particle 10 was higher.
  • the density of the shaped body for which heat treatment was not performed on the metal magnetic particles 10 and the density of shaped bodies that underwent heat treatment at least 400 deg C. and less than 900 deg C. were measured, the former shaped body was measured at 7.50 g/cm 3 and the latter shaped body was measured at 7.66 g/cm 3 . As a result, it was confirmed that the density of the shaped body can be increased by applying heat treatment to the metal magnetic particles 10 at a predetermined temperature.
  • Atomized iron powder prepared through water atomizing was used as the metal magnetic particles 10 .
  • a sieve was used to sort the powder and atomized iron powder sample 1 through sample 7 having different particle diameter distributions were prepared. Heat treatment was performed on these atomized iron powders for 1 hour at a temperature of 800 deg C. in a hydrogen or an inert gas. Next, the coercivity of the heat-treated atomized iron powder was measured using the method described below.
  • a suitable amount of atomized iron powder was formed into pellets using a resin binder to serve as solid pieces to be measured.
  • Magnetic fields of 1 (T:tesla)—>—1 T—>1 T—>-1 T were sequentially applied to the solid pieces and the resulting M(magnetization)-H(magnetic field) loop shapes were determined using vibrating sample magnetometry (VSM).
  • VSM vibrating sample magnetometry
  • the coercivity of the solid piece was calculated from the M-H loop shape, and the obtained coercivity was used as the coercivity of the atomized iron powder.
  • Measurement results are shown in Table 2 along with the particle diameter distribution of the atomized iron powder samples.
  • Table 2 includes the particle diameter distributions and coercivities for insulation-coated iron powders from Hoganas Corp. (product names Somaloy 500 and Somaloy 550).
  • a phosphate film was coated over the heat-treated atomized iron powder to serve as the insulation film 20 , and the coated atomized iron powder was placed in a die and compacted. A pressure of 882 MPa was used.
  • the obtained shaped bodies were heat treated for 1 hour at a temperature of 300 deg C. Then, the coercivity and maximum permeability of the shaped bodies were measured. Also, shaped bodies were prepared using similar steps from Hoganas Corp.'s Somaloy 500 and Somaloy 550, and the coercivity and maximum permeability of these shaped bodies were measured as well. The results from these measurements are shown in Table 2.
  • the present invention can be used primarily to make electrical and electronic parts formed from soft magnetic material compacts such as motor cores and transformer cores.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Soft Magnetic Materials (AREA)
  • Powder Metallurgy (AREA)
US10/595,314 2003-10-15 2004-10-01 Process for producing soft magnetism material, soft magnetism material and powder magnetic core Expired - Fee Related US7601229B2 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
JP2003354940 2003-10-15
JP2003-354940 2003-10-15
JP2003356031 2003-10-16
JP2003-356031 2003-10-16
JP2004024256A JP2005142522A (ja) 2003-10-16 2004-01-30 軟磁性材料の製造方法、軟磁性材料および圧粉磁心
JP2004-024256 2004-01-30
PCT/JP2004/014477 WO2005038829A1 (ja) 2003-10-15 2004-10-01 軟磁性材料の製造方法、軟磁性材料および圧粉磁心

Publications (2)

Publication Number Publication Date
US20070102066A1 US20070102066A1 (en) 2007-05-10
US7601229B2 true US7601229B2 (en) 2009-10-13

Family

ID=34468307

Family Applications (1)

Application Number Title Priority Date Filing Date
US10/595,314 Expired - Fee Related US7601229B2 (en) 2003-10-15 2004-10-01 Process for producing soft magnetism material, soft magnetism material and powder magnetic core

Country Status (4)

Country Link
US (1) US7601229B2 (es)
EP (1) EP1675137B1 (es)
ES (1) ES2381880T3 (es)
WO (1) WO2005038829A1 (es)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2547378C2 (ru) * 2013-07-15 2015-04-10 Общество с ограниченной ответственностью "Научно Технический Центр Информационные Технологии" Способ получения магнитомягкого материала

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100442403C (zh) * 2004-09-30 2008-12-10 住友电气工业株式会社 软磁材料,粉末磁芯和制备软磁材料的方法
CH698498B1 (de) * 2006-03-31 2009-08-31 Alstom Technology Ltd Magnetische abschirmung im stirnbereich des stators eines drehstromgenerators.
DE102008023059B4 (de) * 2008-05-09 2010-06-10 Eto Magnetic Gmbh Verfahren zum Herstellen eines magnetisierbaren metallischen Formkörpers
JP6052960B2 (ja) * 2012-01-12 2016-12-27 株式会社神戸製鋼所 軟磁性鉄基粉末の製造方法
DE102013109993A1 (de) * 2013-09-11 2015-03-12 Endress + Hauser Flowtec Ag Magnetisch-induktives Durchflussmessgerät, Spulenkern und Feldspule
CN111192735A (zh) * 2020-01-17 2020-05-22 深圳市铂科新材料股份有限公司 一种绝缘包覆的金属软磁粉末及其制备方法和用途

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4245026A (en) * 1979-12-26 1981-01-13 Xerox Corporation Production of low density coated magnetic polymer carrier particulate materials
US5925836A (en) * 1997-11-04 1999-07-20 Magnetics International Inc. Soft magnetic metal components manufactured by powder metallurgy and infiltration
JPH11354359A (ja) 1998-06-10 1999-12-24 Hitachi Ltd 圧粉磁心の製造方法及び製造装置
JP2001135515A (ja) 1999-11-05 2001-05-18 Tdk Corp 圧粉磁心
US6309748B1 (en) * 1997-12-16 2001-10-30 David S. Lashmore Ferromagnetic powder for low core loss parts
JP2002064011A (ja) 2000-08-22 2002-02-28 Daido Steel Co Ltd 圧粉磁心
JP2002246219A (ja) 2001-02-20 2002-08-30 Hitachi Powdered Metals Co Ltd 圧粉磁心及びその製造方法
JP2003109810A (ja) 2001-09-28 2003-04-11 Nec Tokin Corp 圧粉磁芯及びその製造方法
JP2003257723A (ja) 2002-02-28 2003-09-12 Daido Steel Co Ltd 複合磁性シートおよびその製造方法
US6702870B2 (en) * 2000-03-10 2004-03-09 Höganäs Ab Method for preparation of iron-based powder and iron-based powder
US20050162034A1 (en) * 2004-01-22 2005-07-28 Wavecrest Laboratories, Inc. Soft magnetic composites

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002121601A (ja) 2000-10-16 2002-04-26 Aisin Seiki Co Ltd 軟磁性金属粉末粒子、軟磁性金属粉末粒子の処理方法、軟磁性成形体、軟磁性成形体の製造方法

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4245026A (en) * 1979-12-26 1981-01-13 Xerox Corporation Production of low density coated magnetic polymer carrier particulate materials
US5925836A (en) * 1997-11-04 1999-07-20 Magnetics International Inc. Soft magnetic metal components manufactured by powder metallurgy and infiltration
US6309748B1 (en) * 1997-12-16 2001-10-30 David S. Lashmore Ferromagnetic powder for low core loss parts
JPH11354359A (ja) 1998-06-10 1999-12-24 Hitachi Ltd 圧粉磁心の製造方法及び製造装置
JP2001135515A (ja) 1999-11-05 2001-05-18 Tdk Corp 圧粉磁心
US6702870B2 (en) * 2000-03-10 2004-03-09 Höganäs Ab Method for preparation of iron-based powder and iron-based powder
JP2002064011A (ja) 2000-08-22 2002-02-28 Daido Steel Co Ltd 圧粉磁心
JP2002246219A (ja) 2001-02-20 2002-08-30 Hitachi Powdered Metals Co Ltd 圧粉磁心及びその製造方法
JP2003109810A (ja) 2001-09-28 2003-04-11 Nec Tokin Corp 圧粉磁芯及びその製造方法
JP2003257723A (ja) 2002-02-28 2003-09-12 Daido Steel Co Ltd 複合磁性シートおよびその製造方法
US20050162034A1 (en) * 2004-01-22 2005-07-28 Wavecrest Laboratories, Inc. Soft magnetic composites

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PCT International Preliminary Report on Patentability issued on Jun. 20, 2006.

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2547378C2 (ru) * 2013-07-15 2015-04-10 Общество с ограниченной ответственностью "Научно Технический Центр Информационные Технологии" Способ получения магнитомягкого материала

Also Published As

Publication number Publication date
WO2005038829A8 (ja) 2005-07-28
WO2005038829A1 (ja) 2005-04-28
EP1675137B1 (en) 2012-02-08
US20070102066A1 (en) 2007-05-10
EP1675137A1 (en) 2006-06-28
EP1675137A4 (en) 2010-01-27
ES2381880T3 (es) 2012-06-01

Similar Documents

Publication Publication Date Title
US7682695B2 (en) Dust core with specific relationship between particle diameter and coating thickness, and method for producing same
EP1912225B1 (en) Soft magnetic material, process for production of the material, powder compressed magnetic core, and process for production of the magnetic core
EP1600987B1 (en) Manufacturing methods for soft magnetic material and powder metallurgy soft magnetic material
EP1716946A1 (en) Soft magnetic material and dust core
EP1737003B1 (en) Soft magnetic material and dust core
EP1918943A1 (en) Soft magnetic material, powder magnetic core, method for manufacturing soft magnetic material, and method for manufacturing powder magnetic core
US7674342B2 (en) Method of producing soft magnetic material, soft magnetic powder, and dust core
EP3300089A1 (en) Dust core, method for producing said dust core, inductor provided with said dust core, and electronic/electrical device on which said inductor is mounted
US20110104476A1 (en) Soft magnetic material, motor core, transformer core, and method for manufacturing soft magnetic material
JP2005286145A (ja) 軟磁性材料の製造方法、軟磁性粉末および圧粉磁心
US7601229B2 (en) Process for producing soft magnetism material, soft magnetism material and powder magnetic core
KR20060054372A (ko) 연자성 재료, 압분자심, 트랜스 코어, 모터 코어 및압분자심의 제조방법
US7588648B2 (en) Soft magnetism material and powder magnetic core
EP1662518A1 (en) Soft magnetic material and method for producing same
EP1662517A1 (en) Soft magnetic material and method for producing same
JP4586399B2 (ja) 軟磁性材料、圧粉磁心、および軟磁性材料の製造方法
JP2005142522A (ja) 軟磁性材料の製造方法、軟磁性材料および圧粉磁心
JP7016713B2 (ja) 圧粉磁心および磁心用粉末
US20070036669A1 (en) Soft magnetic material and method for producing the same
KR101504131B1 (ko) 저철손 Fe-P 연자성 소재 및 그 제조방법
JP2021036577A (ja) 圧粉磁芯
JP2006049789A (ja) 軟磁性材料、圧粉磁心および圧粉磁心の製造方法
JP2005142533A (ja) 軟磁性材料および圧粉磁心

Legal Events

Date Code Title Description
AS Assignment

Owner name: SUMITOMO ELECTRIC INDUSTRIES, LTD., JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:TOYODA, HARUHISA;KUGAI, HIROKAZU;HIROSE, KAZUHIRO;AND OTHERS;REEL/FRAME:017436/0759;SIGNING DATES FROM 20060321 TO 20060324

STCF Information on status: patent grant

Free format text: PATENTED CASE

FEPP Fee payment procedure

Free format text: PAYOR NUMBER ASSIGNED (ORIGINAL EVENT CODE: ASPN); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

FPAY Fee payment

Year of fee payment: 4

FPAY Fee payment

Year of fee payment: 8

FEPP Fee payment procedure

Free format text: MAINTENANCE FEE REMINDER MAILED (ORIGINAL EVENT CODE: REM.); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

LAPS Lapse for failure to pay maintenance fees

Free format text: PATENT EXPIRED FOR FAILURE TO PAY MAINTENANCE FEES (ORIGINAL EVENT CODE: EXP.); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

STCH Information on status: patent discontinuation

Free format text: PATENT EXPIRED DUE TO NONPAYMENT OF MAINTENANCE FEES UNDER 37 CFR 1.362

FP Lapsed due to failure to pay maintenance fee

Effective date: 20211013